US20020142471A1 - Methods and systems for moving fluid in a microfluidic device - Google Patents

Abstract

The present invention relates to a system and method for moving samples, such as fluid, within a microfluidic system using a plurality of gas actuators for applying pressure at different locations within the microfluidic. The system includes a substrate which forms a fluid network through which fluid flows, and a plurality of gas actuators integral with the substrate. One such gas actuator is coupled to the network at a first location for providing gas pressure to move a microfluidic sample within the network. Another gas actuator is coupled to the network at a second location for providing gas pressure to further move at least a portion of the microfluidic sample within the network. A valve is coupled to the microfluidic network so that, when the valve is closed, it substantially isolates the second gas actuator from the first gas actuator.

Description

RELATED APPLICATIONS
• This application is a continuation-in-part of application Ser. No. 10/014,519, filed Dec. 14, 2001. This application is also a continuation-in-part of application Ser. No. 09/953,921, filed Sep. 18, 2001, and claims priority of provisional application No. 60/307,638 filed Jul. 26, 2001. This application is also a continuation-in-part of application Ser. No. 09/819,105, filed Mar. 28, 2001. Each of the above-mentioned applications are incorporated herein by reference.[0001]
FIELD OF THE INVENTION
• The present invention relates to methods and systems for processing samples using microfluidic systems. More particularly, the invention relates to moving fluid samples within a microfluidic system.[0002]
BACKGROUND
• Microfluidic devices are typically formed of substrates (made of silicon, glass, ceramic, plastic and/or quartz) which include a network of micro-channels through which fluid flows under the control of a propulsion mechanism. The micro channels typically have at least one dimension which is on the order of nanometers to hundreds of microns.[0003]
• Microfluidic devices process minute amounts of fluid sample to determine the physical and chemical properties of the sample. Microfluidic devices offer several advantages over a traditional macro-scale instrumentation. For example, in general, they require substantially smaller fluid samples, use far less reagent, and process these fluids at substantially greater speeds than macro-scale equipment.[0004]
• Electric fields are used as a propulsion mechanism for some microfluidic devices. In such devices, a high voltage, on the order of kilovolts, is applied across electrodes within the device to thereby generate an electric field in the micro channels. The field imposes a force on ions within the fluid, thereby propelling the ions through the micro channel. The fluid itself may also be propelled by the motion of ions moving within the fluid.[0005]
• Gas pressure is also used to propel fluid through micro channels. In some devices, a source of pressurized gas, external to the microfluidic device, is connected to the microfluidic device to supply a gas pressure, which propels the fluid. Gas pressure may also be generated by a heated chamber within the microfluidic device itself to propagate fluid within a micro channel.[0006]
SUMMARY OF THE INVENTION
• In general, the invention relates to a system and method for moving samples, such as fluids, within a microfluidic system. In one aspect, the invention relates to the use of a plurality of gas actuators for applying pressure at different locations within the microfluidic system to thereby supply force for moving samples. For example, in one embodiment, a first gas actuator provides a gas pressure sufficient to move a first sample from a first location to a second location of the microfluidic device. A second gas actuator provides a gas pressure to move another sample from a third location to a fourth location of the microfluidic device.[0007]
• In another example, a plurality of gas actuators cooperate to move the same fluid sample. A first gas actuator provides a gas pressure sufficient to move the microdroplet between first and second processing zones of the microfluidic device, and a second gas actuator provides a gas pressure to move the microdroplet to a third processing zone.[0008]
• In preferred embodiments, the plurality of actuators are integral with a microfluidic network through which the microfluidic samples flow. For example, a plurality of gas actuators can be fabricated in the same substrate which forms the microfluidic network. One such gas actuator is coupled to the network at a first location for providing gas pressure to move a microfluidic sample within the network. Another gas actuator is coupled to the network at a second location for providing gas pressure to further move at least a portion of the microfluidic sample within the network.[0009]
• In other aspect, the invention relates to the use of valves with the plurality of actuators. For example, in one embodiment, a valve is coupled to a microfluidic network so that, when the valve is closed, it substantially isolates the second gas actuator from the first gas actuator. Such valves can control the direction of the propulsive force of the actuatators by preventing the expanding gas from traveling in certain directions, while permitting it to expand in the desired direction. They also extend the range over which an actuator can propel a microdroplet, by preventing the gas from dissipating in certain in areas upstream from the microdroplet.[0010]
BRIEF DESCRIPTION OF THE DRAWINGS
• The present invention is described below in reference to the following drawings, in which:[0011]
• FIG. 1 shows a microfluidic system according to the invention;[0012]
• FIG. 2 shows an expanded view of a microfluidic device.[0013]
• FIG. 3 shows a schematic of a microfluidic device of the microfluidic system of FIG. 1;[0014]
• FIG. 4, shows a top view of the microfluidic device of FIG. 3;[0015]
• FIG. 5 shows a partial cross-sectional view of the microfluidic device of FIG. 4;[0016]
• FIG. 6 shows a partial cross-sectional view of an upper substrate from the microfluidic device of FIG. 2;[0017]
• FIG. 7 shows a second partial cross-sectional view of an upper substrate from the microfluidic device of FIG. 2;[0018]
• FIG. 8[0019]ashows a top view of a microdroplet preparation zone of the microfluidic device of FIG. 4 before preparation of a microdroplet;
• FIG. 8[0020]bshows cross sectional view of the microdroplet preparation zone of FIG. 8a;
• FIG. 9[0021]ashows a top view of a microdroplet preparation zone of the microfluidic device of FIG. 4 after preparation of a microdroplet;
• FIG. 9[0022]bshows a cross sectional side view of the microdroplet preparation zone of FIG. 9a;
• FIGS. 10[0023]a-10cshow cross sectional side views of a capillary assisted fluid barrier of the present invention;
• FIGS. 11[0024]a-11cshow top views of a fluid barrier comprising a vent;
• FIGS. 12[0025]aand12bshow top views of the lysing module of the microfluidic device of FIG. 4, before and after preparation of a lysed sample;
• FIGS. 13[0026]aand13bshow a second embodiment of a lysing module of the invention;
• FIG. 14 shows a pulsing circuit associated with the lysing module of FIG. 4; and[0027]
• FIGS. 15[0028]a-15cshow a second microdroplet preparation module of the invention.
DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT
• The present invention relates to microfluidic systems and methods for processing materials, such as samples and reagents. More specifically, the invention relates to microfluidic systems and methods for moving fluids within a microfluidic system. In the embodiment described below, the fluid includes particles which tend to move with the fluid. The fluid component of the particle-containing fluid is a gas or, preferably, a liquid. The particles of the particle-containing fluid are preferably whole cells, such as bacterial cells or cells of an animal, such as a human. However, they may include intracellular material from such cells. For example, a system of the invention may be used to process a sample of bacterial cells to determine whether the bacteria are pathogenic.[0029]
• A. System Overview[0030]
• FIG. 1 depicts a[0031]microfluidic system100 that includes amicrofluidic device110 andcorresponding cartridge120, which receive one or more fluid samples and process the samples under the control of computer127 and data acquisition and control board (DAQ)126.
• Computer[0032]127 preferably performs high level functions, such as supplying a user interface that allows a user to select desired operations, notifying theDAQ126 as to the selected operations, and displaying for the user the results of such operations. These operations include, for example, subjecting a sample to process steps within the various process zones of the microfluidic device. The computer127 may be a portable computer to facilitate transport of the microfluidic system.
• Computer[0033]127 is connected to DAQ126 viaconnection128, which provides data I/O, power, ground, reset, and other functional connectivity. Alternatively, awireless link132 between the computer127 and theDAQ126 may be provided for data and control signal exchange via wireless elements132(a) and132(b). Where the data link is a wireless link, for example, theDAQ126 may have separate power source, such as a battery.
• In general,[0034]DAQ126 controls the operation ofmicrofluidic device110 in accordance with the high level instructions received from computer127. More specifically, to implement a desired operation requested by computer127,DAQ126 supplies the appropriate electrical control signals tocartridge120 viacontacts125.
• [0035]Cartridge120 provides electrical andoptical connections121 for electrical and optical signals between theDAQ126 and themicrofluidic substrate110, thereby allowingDAQ126 to control the operation of the substrate.
• The[0036]chip carrier cartridge120 is shown being inserted into (or removed from) an interface hardware receptacle of theDAQ126 having electrical andoptical contacts125 standardized to mate with a correspondingcontacts121 of thechip carrier cartridge120. Most contacts are for electrical signals, while certain ones are for optical signals (IR, visible, UV, etc.) in the case of optically-monitored or optically-excited microfluidic processors. Alternatively (not shown), theentire DAQ126 may be a single ASIC chip that is incorporated into theChip Carrier Cartridge120, whereincontacts121,125 would become conductive pathways on a printed circuit board.
• B. Microfluidic Device[0037]
• FIG. 2 illustrates the general structure of a preferred type of microfluidic device. The device includes an[0038]upper substrate130, which is bonded to alower substrate132 to form a fluid network.
• The[0039]upper substrate130 depicted in FIG. 2 is preferably formed of glass and has amicrofluidic network134 in itsbottom surface136. Those skilled in the art will recognize that substrates composed of silicon, glass, ceramic, plastic, and/or quartz are all acceptable in the context of the present invention.
• The microfluidic network includes a plurality of zones. The number of zones, as well as the overall topology of the microfluidic network, will depend upon the particular application which the microfluidic device is designed to perform. The zones of the microfluidic device may have any cross-sectional shape, such as generally arcuate or generally polygonal. For example, a zone may include channels, chambers or other substantially enclosed spaces. By “substantially enclosed” it is meant that materials enter or exit the zones only through predetermined pathways. Examples of such pathways include channels, microchannels and the like, which interconnect the various zones. The zones preferably have at least one micro-scale dimension, such as less than about 250 μm or, more preferably, less than about 75 μm.[0040]
• The channels and chambers of the microfluidic network are etched in the[0041]bottom surface136 of theupper substrate130 using known photolithographic techniques. More specifically, transparent templates or masks containing opaque designs are used to photo-define objects on the surface of the substrate. The patterns on the templates are generated with computer-aided-design programs and can delineate structures with line-widths of less than one micron. Once a template is generated, it can be used almost indefinitely to produce identical replicate structures. Consequently, even extremely complex microfluidic networks can be reproduced in mass quantities and at low incremental unit cost. Alternatively, if a plastic material is used, the upper substrate may be formed using injection molding techniques, wherein the micro-channels are formed during the molding process.
• The[0042]lower substrate132 may include aglass base138 and anoxide layer140. Withinoxide layer140,resistive heaters142 andelectric leads144 are formed using photolithographic techniques. The leads144 connect toterminals146 which are exposed at the edge of the substrate to permit electrical connection tocartridge120, thereby permitting DAQ126 to control the heaters. More specifically, to activate aheater142,DAQ126 applies a voltage across a pair of terminals146 (via cartridge120) to supply current throughleads146 andheater142, thereby heating theresistive heater element142.
• [0043]Metal heater elements142 are positioned so that, when the upper and lower substrates are bonded together, the heaters reside directly beneath certain regions of the fluid network of the upper substrate so as to be able to heat the contents of these regions. Thesilicon oxide layer140 prevents theheating elements142 from directly contacting with material in the microfluidic network.
• The[0044]oxide layer140,heating elements142, and resistive leads144 are fabricated using well-known photolithographic techniques, such as those used to etch microfluidic network.
• FIG. 3 illustrates a top-down view of[0045]microfluidic device110. As shown, the substrate has asample input module150 andreagent input module152 to allow sample and reagent materials, respectively, to be input todevice110. Preferably,input modules150,152 are disposed to allow automatic material input using a computer controlledlaboratory robot154.
• The substrate also includes[0046]process modules156,158,160,166 and162 for processing the sample and reagent materials. Within these process modules, a sample may be subjected to various physical and chemical process steps. For example,enrichment module156 prepares a fluid sample having a relatively high concentration of cell particles, lysingmodule160 releases intracellular material from the cell particles, and mixingmodule166 mixes the resultant sample with certain reagents. As another example, anamplification process module162 may be used to amplify and detect minute quantities of DNA within a sample.
• Various modules of[0047]microfluidic device110 are connected, such as bychannels164, to allow materials to be moved from one location to another within thedevice110.Actuators168,170,172 associated with the microfluidic device provide a motive force, such as a gas pressure, to move the sample and reagent material along the channels and zones. For example, afirst actuator168 moves material downstream fromprocess module156 to processmodule158. Upon completion of processing withinprocess module158, asecond actuator170 moves material downstream to mixingprocess module160. Subsequently,actuator170 or an additional actuator moves the material to mixingmodule166, where the material mixes with a reagent moved byactuator172. Finally,actuator172, or another actuator, moves the mixed material tomodule162.
• Because each actuator is preferably responsible for moving materials within only a subset of the modules of[0048]device110, sample materials can be controlled more precisely than if a single actuator were responsible for moving material throughout the entire device. The various functional elements, ofmicrofluidic device110, including the actuators, are preferably under computer control to allow automatic sample processing and analysis.
• C. Multiple Actuators[0049]
• The various actuators of[0050]microfluidic device110 cooperate to move material between different locations ofmicrofluidic device110. For example,actuator168 moves material, such as an enriched sample, between anenrichment zone931 and amicrodroplet preparation module158.Actuator170 prepares a microdroplet from the enriched sample and, in so doing, moves the microdroplet to a lysing zone950.Actuator170 is used to move material from the lysing zone950 to mixingmodule166. It should be noted, however, that another actuator may be disposed intermediate between lysing zone950 and microdroplet preparation zone to move the lysed sample downstream to themixing module166.
• Actuators of[0051]device110 may also cooperate in moving two amounts of material simultaneously. For example, as described above,actuator172 andactuator170 cooperate to mix reagent and lysed microdroplets. Such cooperative actuators can be controlled independently of one another to ensure proper mixing. For example, if one material is known to be more viscous, the motive force moving that material can be increased independently of the motive force moving the other material.
• The multiple actuators and modules of[0052]microfluidic device110 are preferably operatively connectable and isolatable by the valves of microfluidic device. For example, a closed state of either ofvalves915,216 operatively isolatesmicrodroplet preparation module170 fromenrichment module156. Thus, one or more actuators can be used to move materials between predetermined locations withinmicrofluidic device110, without perturbing or contacting material present in an operatively isolated module. The ability to operatively connect and isolate desired modules is advantageous in microfluidic devices having many process functions. Further, these valves also control the direction of the propulsive force of the actuatators by preventing the expanding gas from traveling in certain directions, while permitting it to expand in the desired direction. This also extends the range over which an actuator can propel a microdroplet, by preventing the gas from dissipating in certain in areas upstream from the microdroplet.
• The following demonstrates the cooperative operation of such multiple actuators in an example embodiment having a plurality of processing modules, namely an[0053]enrichment zone915, amicrodroplet preparation module158, acell lysing module160, amixing module166 and a DNA manipulation module167.
• 1. Enrichment Module[0054]
• a. Structure of Enrichment Module[0055]
• Referring to FIGS. 4 and 5, a microfluidic device[0056]901 includes anenrichment module156 for concentrating samples received therein. These samples include particle-containing fluids, such as bacterial cell-containing fluids. In general,enrichment module156 receives a flow of particle-containing fluid from aninput port180 ofinput module150, and allows the fluid to pass through the zone while accumulating particles within the zone. Thus, as more fluid flows through the zone, the particle concentration increases within the module. The resultant concentrated fluid sample is referred to herein as an enriched particle sample.
• The enrichment module includes an enrichment zone[0057]931 (FIG. 5), a flow throughmember900,valves915,919, andsample introduction channel929.Valve919 is connected between the flow throughmember900 andactuator168 as shown, andvalve915 is connected between the flow through member and adown stream channel937 which leads toprocess module158. These valves may be of any type suitable for use in a microfluidic device, such as thermally actuated valves, as discussed in co-pending application Ser. No. 09/953,921, filed Sep. 9, 2001. The valves may be reversible between the open and closed states to allow reuse ofenrichment module931.
• The flow through member is also connected to the[0058]sample input module150 via thesample introduction channel929 to allow fluid to flow into the enrichment zone.Valve913 is connected to this sample introduction channel to control the in-flow and outflow of fluid from the input port.
• FIG. 5 is a cross-sectional view of the enrichment zone which shows the flow through member in greater detail. As shown, flow through[0059]member900 has first andsecond surfaces941,943.First surface941 is preferablyadjacent enrichment chamber931.Second surface941 is preferably spaced apart from theenrichment chamber931 by flow throughmember900. Flow throughmember900 is preferably formed of a material having pathways smaller than the diameter of the particles to be enriched, such as pores of less than about 2 microns in diameter, for example, about 0.45 microns. Suitable materials for constructing flow throughmember900 include, for example, filter media such as paper or textiles, polymers having a network of pathways, and glassy materials, such as glass frits.
• FIGS. 6 and 7 depict cross sectional views of[0060]upper substrate130 that illustrate anenrichment zone931. As shown, fluid exitsenrichment zone931 throughsurface941, passes throughmember900 and enters aspace400.Space400 may include anabsorbent material402 to absorb the exiting fluid. Thus,space400 preferably provides a substantially self-contained region in which fluid exiting the enrichment zone can collect without contacting exterior portions of themicrofluidic system100.
• [0061]Space400 is formed during the fabrication ofupper substrate130. As discussed above, microfluidic features, such as zones and channels, are fabricated atsurface136 ofsubstrate130.Space400, however, is fabricated at asurface137, which is preferably disposed on the other side ofsubstrate130, oppositesurface136. Thus, even whensurface136 is mated withlower substrate132, fluid can exitenrichment zone931 via flow throughmember900.
• Flow through[0062]member900 andabsorbent material402 do not require adhesives or other fasteners for positioning withinsubstrate130. Rather flow throughmember900 andabsorbent material402 may be formed of a shape and size that substantially corresponds tospace400. Friction then holds flow throughmember900 andabsorbent material402 in place once they are positioned inspace400. Any residual gap atlocations404 between flow throughmember900 andsubstrate130 should be small enough to prevent particles from exitingenrichment zone931 through thegap404. Naturally, adhesive or other fastening means may be used to secure flow throughmember900 orabsorbent material402.
• In an alternative embodiment, a flow through member is formed integrally with a substrate by using microfabrication techniques, such as chemical etching, that introduce pores or other pathways into the substrate. The pores provide fluid passage between[0063]enrichment zone931 and an outer portion of the substrate.
• b. Operation of Enrichment Module[0064]
• To enrich a sample, the device[0065]901 operates as follows. Referrring to FIG. 4,valves915,919 are initially closed, andvalve913 is open. A particle-containing fluid is introduced intoinput port180. Sincevalve913 is open, it allows the sample to pass alongchannel929 intoenrichment zone931. Alternatively,enrichment zone931 can be configured to receive samples directly, such as by injection. Sincevalves915 and919 are closed, fluid is substantially prevented from escaping intoactuator977 anddownstream channel937.
• Thus, flow through[0066]member900 provides the only path for fluid to exit the enrichment channel. Fluid passes throughsurface941 and exitsenrichment zone931 viasecond surface943, while particles accumulate within the zone.Enrichment zone931 can therefore receive a volume of fluid that is larger than the volume of theenrichment chamber931. Thus, as fluid flows through the chamber, the concentration of particles within the chamber increases relative to the concentration in the particle-containing fluid supplied at the sample input. Where the particles are cells, the concentration or number of cells inzone931 preferably becomes great enough to perform a polymerase chain reaction (PCR) analysis of polynucleotides released from the cells in a downstream processing module.
• [0067]Enrichment zone931 thus prepares an enriched particle sample from particles of particle-containing fluids received therein. The enriched particle sample has a substantially higher ratio of particles per volume of fluid (PPVF) than the corresponding ratio of the particle-containing fluid received by the enrichment zone. The PPVF of the enriched particle sample is preferably at least about 25 times, preferably about 250 times, more preferably about 1,000 times greater than the PPVF of the particle-containing fluid.
• After a sufficient volume of particle containing fluid has been received by[0068]enrichment zone931,valve913 is closed thereby blocking further flow of fluid into the enrichment zone, and preventing material inzone931 from returning to thesample introduction port180.Valves915,919 are then opened, preferably upon actuating heat sources associated therewith. When opened,valve919 allowsactuator168 to push enriched sample, andvalve915 allows the enriched sample to move downstream.
• [0069]Actuator168 provides a motive force that moves the enriched particle sample fromenrichment zone931.Actuator168 is preferably a gas actuator, which provides a gas pressure upon actuation of aheat source975, which is in thermal communication with a volume ofgas977. Actuation ofheat source975 raises the temperature and, therefore the pressure, ofgas977. The flow through member and the fluid therein substantially prevents gas from escaping the enrichment zone. Thus, the resulting gas pressure moves the enriched particle sample downstream from theenrichment zone931.
• The gas actuator may include elements to facilitate alternative pressure generation techniques such as chemical pressure generation. In another embodiment, the actuator may decrease a volume of gas associated with an upstream portion of the enrichment zone to thereby create a pressure differential across the sample that moves the sample from the enrichment zone. An example of such an element is a mechanical actuator, such as a plunger or diagram.[0070]
• Rather than generating a positive pressure upstream from the enrichment zone, the gas actuator may decrease a pressure downstream from the zone relative to a pressure upstream. For example, the gas actuator may include a cooling element in thermal contact with a volume of gas associated with a downstream portion of the zone. Contraction of the gas upon actuating the cooling element creates a gas pressure difference between the upstream and downstream portions of the enrichment zone to move the enriched particle sample from the enrichment zone. Alternatively, a mechanical actuator may be used increase a volume of gas associated with a downstream portion of the enrichment zone to thereby decrease the pressure of the gas and move the enriched particle sample from the enrichment zone.[0071]
• The enriched particle sample is preferably moved downstream with essentially no dilution thereof, i.e., the concentration of the enriched particles is not substantially decreased upon movement from the[0072]enrichment zone931. Thus, removal of particles from the enrichment channel of the present invention does not require diluting or otherwise contacting the particles with a fluid different from the fluid of the particle-containing fluid introduced to the enrichment channel. In contrast, in systems that concentrate substances by surface adsorption, removal of the adsorbed substances requires an elution fluid, which contacts and thereby dilutes the substances.
• Upon removal from the enrichment zone of the present invention, the enriched particle sample is preferably received by[0073]downstream channel937.Downstream channel937 leads to other processing modules, which perform further processing of the enriched particle sample. In the embodiment of FIG. 3, the enriched particle sample is received by amicrodroplet preparation module158, which prepares a microdroplet sample comprising a portion of the enriched particle sample.
• 2. Microdroplet Preparation Module[0074]
• a. Characteristics of a Microdroplet[0075]
• A[0076]microdroplet802 is a discrete sample having a predetermined volume between, for example, about 1.0 picoliter and about 0.5 microliters. Thus, microdroplets prepared by microdroplet preparation module provide a known amount of sample for further processing. The volume of the microdroplet prepared by the microdroplet preparation module is preferably essentially independent of the viscosity, electrical conductivity, and osmotic strength of the fluid of the microdroplet.
• [0077]Microdroplet802 is preferably defined by upstream and downstream boundaries each formed by a respectivegas liquid interface804,806. The liquid of the interface is formed by a surface of a liquid forming the microdroplet. The gas of the interface is gas present in the channels microfluidic of microfluidic device901.
• b. Structure and Operation of the Microdroplet Preparation Module[0078]
• Referring to FIGS. 8[0079]a-8band9a-9b,microdroplet preparation module158 prepares amicrodroplet802 from a microfluidic sample received therein. This module includes amicrodroplet preparation zone800, apositioning element979, agas actuator170, and avalve216 which cooperate to preparemicrodroplet800 from microfluidic samples received from the enrichment zone.
• As explained above,[0080]actuator168 of the enriched zone pushes the enriched sample into themicrodroplet preparation zone800. The enriched sample moves until reachingpositioning element979. In general, a positioning element inhibits the downstream progress of a microfluidic sample to thereby position the sample at a desired location. However, as explained more fully below, the positioning element does not permanently inhibit progress of the sample. Rather, it allows the microfluidic sample to continue downstream at a predetermined later time.
• The leading edge of[0081]microfluidic sample808 that reachespositioning element979 is positioned downstream from anopening820 ofgas actuator170. Accordingly, afirst portion821 ofmicrofluidic sample808 is disposed upstream from opening820 and asecond portion822 ofmicrofluidic sample808 is disposed downstream fromopening820.
• Referring to FIGS. 8[0082]a-8b,gas actuator170 is actuated, such as byDAQ126, to thereby generate a gas pressure sufficient toseparate microdroplet802 from thesecond portion822 ofmicrofluidic sample808. The gas pressure is preferably provided by the actuation of aheat source958, which heats a volume of gas associated with gas actuator957. As the pressure increases, the gas expands, thereby separating amicrodroplet802 from the rest ofsample808.Microdroplet802 may comprise only a portion, such as less than about 75%, or less than about 50%, ofmicrofluidic sample808 received bymicrodroplet preparation zone800. The dimensions ofmicrodroplet802 are determined by the volume of the channel betweenfluid barrier979 andopening820. For example, for a channel having a uniform cross-sectional area, a length l₁ofmicrodroplet802 corresponds to a distance d₄betweenpositioning element979 andopening820. Thus, a microfluidic device can be configured to prepare microdroplets of any volume by varying the length between the fluid barrier and corresponding actuator opening.
• Continued actuation of[0083]gas actuator170 overcomes the inhibitory effect ofpositioning element979, thereby drivingmicrodroplet802 to a location downstream ofmicrodroplet preparation zone800 while thesecond portion822 of the microfluidics sample moves upstream frommicrodroplet802 tocell lysis module160.
• 3. Cell Lysis Module[0084]
• Referring back to FIG. 3, a[0085]lysing module160 receives themicrodroplet802 prepared bymicrodroplet preparation zone800. In general, lysingmodule160 releases material from inside the particles, such as by releasing intracellular material from cells.
• As shown in FIGS. 4 and 12, lysing[0086]module160 includes a lysing zone950, a lysing mechanism within the lysing zone (such as electrodes954), and a ventedpositioning element200 positioned upstream from the lysing zone. The lysing mechanism preferably includes a set of electrodes or other structures for generating electric fields within the lysing zone. The vented positioning element preferably includes avent202, avalve204, and asecond positioning element206 for inhibiting fluid from flowing into the vent.
• As explained above,[0087]actuator170 of themicrodroplet preparation module158 drives a microdroplet intocell lysis module160. As the microdroplet moves intomodule160, ventedpositioning element200 positions microdroplet802 in a lysing position with respect toelectrodes954. More specifically, as the microdroplet arrives in lysingmodule160 it passes the opening ofpositioning element200, becausesecond positioning element206 inhibits the microdroplet from flowing intovent202. When the rear end of the microdroplet passes the opening ofbarrier200, the propulsion gas fromactuator170 dissipates throughvent202, thereby substantially equalizing gas pressure upstream ofmicrodroplet802 with a pressure downstream ofmicrodroplet802. Thus, the microdroplet stops movement at a lysing position just downstream frombarrier200. Preferably, in the lysing position, substantially all ofmicrodroplet802 is disposed between anupstream edge212 and adownstream edge214 ofelectrodes954.
• After[0088]microdroplet802 is placed in the cell lysing position, a pulse circuit ofDAQ126 supplies a pulsed voltage signal acrosselectrodes954. In response,electrodes954 generate a pulsed electric field in the vicinity of the electrodes. Because the microdroplet is position in this vicinity, cells within the microdroplet are subjected to the pulsed field. Preferably, substantially all of the cells, such as greater than about 75%, of the microdroplet are subjected to an electric field sufficient to release intracellular material therefrom. The lysing module thus prepares a lysed microdroplet comprising a predetermined amount of sample.
• A preferred pulse circuit is shown in FIG. 14. In general, this circuit generates a sequence of voltage pulses that yields a corresponding sequence of electrical field pulses in the vicinity of[0089]electrodes954 having an amplitude and duration sufficient to release a desired amount of intracellular material from cells within the microdroplet.
• Intracellular material present in lysed microdroplet is accessible to further process steps. For example, DNA and/or RNA released from cells is accessible for amplification by a polymerase chain reaction. As used herein, the term lysing does not require that the cells be completely ruptured. Rather, lysing refers to the release of intracellular material. For example, rather than rupturing the cells, the electric field may increase the porosity of cell membranes by an amount that allows release of intracellular material without permanent rupture of the membranes.[0090]
• Other lysing mechanisms may also be employed to release intracellular material from cells. For example, material may be released by subjecting cells to other forces including for example osmotic shock or pressure. Chemicals, selected from the group of surfactants, solvents, and antibiotics may be contacted with the cells. Mechanical shear methods may also be used to release intracellular materials.[0091]
• The lysed microdroplet may be moved downstream to mixing[0092]module160 for further processing. To move lysed microdroplet downstream,valve216, which is disposed upstream of lysing zone950, is closed.Valve204 is also closed to prevent gas from exiting lysing zone950 via vent.Actuator170 is then actuated, as described above, to provide a gas pressure sufficient to move lysed microdroplet downstream of lysing zone950.
• In an alternative embodiment, a[0093]lysing module300, as shown in FIGS. 13a,13b, includes a lysingzone302 which is configured to prepare a lysedmicrodroplet304 of predetermined volume from amicrofluidic sample306, which may have an indeterminate volume.Lysing zone302 preferably includes a lysing mechanism such aselectrodes308. Electrical leads310 provide a connection to a pulse circuit ofDAQ126, viacontacts112,chip carrier120, andcontacts125. Apositioning element312 is disposed downstream of lysingzone302. Anactuator314 is disposed upstream from lysing zone.Actuator314 preferably includes asecond positioning element316 to prevent fluid from the microfluidic sample from entering therein.
• [0094]Lysing zone302 operates as follows. Themicrofluidic sample306 enters lysingzone302 and moves downstream until adownstream interface316 of themicrofluidic sample306encounters positioning element312. Thepositioning element312 preferably increases a surface tension of the downstream interface of themicrofluidic sample306, thereby inhibiting further downstream movement and positioning a portion of the microfluidic sample in a lysing position with respect toelectrodes308. The lysing position is defined as the location of the portion of the microfluidic sample disposed downstream ofactuator314 and upstream ofpositioning element312. Preferably,actuator314 andpositioning element312 are disposedadjacent electrodes308 such that substantially all of the material present in the lysing position is subjected to the electric field upon actuatingelectrodes308.
• Actuation of[0095]electrodes308 in the embodiment described above, provides an electrical field sufficient to release intracellular material from cells present in the portion of the microfluidic sample in the lysing position. Once a sufficient amount of intracellular material has been released,actuator314 is actuated to prepare lysedmicrodroplet304 from themicrofluidic sample306.Actuator314 preferably provides a gas pressure sufficient to move the lysedmicrodroplet304 to a downstream portion of a microfluidic device such asmixing module166.
• 4. Mixing Module and Reagent Input Module[0096]
• Referring back to FIG. 4, a lysed sample prepared by lysing[0097]module160 is received by mixingmodule166. Mixingmodule166 includes amixing zone958. In this zone, the lysed cell sample is contacted, such as by mixing, with an amount of reagent received from thereagent source module152.Reagent source module152 includes a reagent microdroplet preparation zone (RMPZ)434, which preferably operates to prepare a microdroplet having a predetermined volume of reagent.
• a. Reagent Input Module[0098]
• [0099]Reagent input module152 is essentially the same asmicrodroplet formation module158, however, it is specifically designed for formation of a microdroplet of reagent having a predetermined volume which will yield a desired ratio of reagent to sample when mixed with the microdroplet fromcell lysing module160.Module152 includes an input port420, avalve422, and anactuator172, each of which joins areagent source channel428. Anoverflow channel424, which also joinsreagents source channel428, may also be provided.Actuator172 may include asecond positioning element432 to prevent liquid from entering therein.
• Reagent materials, which preferably comprise at least one liquid, are introduced via input port[0100]420, such as with a pipette or syringe. Examples of suitable reagent materials include substances to facilitate further processing of the lysed cell sample, such as enzymes and other materials for amplifying DNA therein by polymerase chain reaction (PCR). The reagent material moves downstream withinreagent source channel428 until a downstream portion of the reagent material contacts apositioning element426. Any additional reagent material that continues to be received within reagent source module preferably entersoverflow channel424. When the introduction of reagent is complete,valve422 is closed to prevent reagent from exiting reagent source channel via reagent source port420.
• b. Mixing Module[0101]
• Mixing[0102]zone958 of the mixing module includes adjoined first andsecond channels410,412. Materials moving downstream toward mixingzone958 contact one another and preferably mix therein. Because of the micro-scale dimensions of mixingzone958, the sample and reagent materials preferably mix by diffusion even in the absence of other sources of mass transport, such as mechanical agitation. It should be understood however, that agitation forces, such as acoustic waves may be applied to enhance mixing within mixingzone958.
• c. Operation of Mixing Module and Reagent Input Module[0103]
• [0104]Reagent source module152 and mixingmodule166 preferably operate as follows. When a lysed sample from lysing zone950 is ready to be mixed with reagent material,actuator172 is actuated to prepare a microdroplet of reagent. The microdroplet of reagent is prepared from the portion of reagent material downstream of anopening430 ofactuator172 and upstream of positioning element427. Thus, assuming that the dimensions of thereagent source channel428 are constant, the volume of the microdroplet of reagent is determined by the distance between thepositioning element426 and theactuator opening430.
• The microdroplet of reagent moves downstream toward channel[0105]412 of reagent mixing zone. Meanwhile, a sample of lysed material, such as a lysed microdroplet, is moved downstream from lysing zone950 towardchannel410 of mixingzone958.Actuator170 may provide the motive force to move the lysed microdroplet downstream. Alternatively, as discussed above, another actuator may be disposed upstream of lysing zone950 but downstream ofactuator170 to provide the necessary motive force.
• The sample and reagent material enter a[0106]downstream channel438 of mixingzone958, where the materials contact and mix. Because both the lysed sample and reagent material are mixed in the form of microdroplets, mixingzone958 prepares an amount of mixed material having a predetermined ratio of sample to reagent. The volumes of microdroplets prepared withinmicrofluidic device110 are preferably independent of physical properties, such as viscosity, electrical conductivity, and osmotic strength, of the microdroplets. Thus, mixingzone958 prepares an amount of mixed material having a sample to reagent material that is also independent of the physical and chemical properties of the mixed materials. Avent440, which is downstream of the various zones of themicrofluidic device110 ensures that downstream pressure buildup does not inhibit downstream movement of samples withinmicrofluidic device110.
• 5. DNA Manipulation Module[0107]
• The mixed lysed cell sample and reagent are received within a[0108]DNA manipulation zone971 ofDNA manipulation module162.Module162 can perform, for example, restriction, digestion, ligation, hybridization and amplification of DNA material. In one embodiment,DNA manipulation zone971 is configured to perform PCR amplification of nucleic acids present within the lysed cell sample.Vent440 prevents pressure from increasing withinzone971 as the lysed cell sample and reagent are being introduced thereto. Valves972 and973 ofDNA manipulation module162 may be closed to prevent substances therein zone from exiting, such as by evaporation, during PCR amplification. The DNA manipulation zone is configured with heat sources under control of computer127 to allow thermal cycling of DNA manipulation zone during amplification, as understood by one of skill in the art.
• System[0109]901 includes also includes a detector981 to detect the presence of amplified polynucleotides produced by PCR. Detector981 is preferably an optical detector in optical communication, such as by a fiber optic981, withzone971. A light source, such as a laser diode, introduces light toDNA Manipulation zone971 to generate fluorescence indicative of the amount of amplified polynucleotides present therein. The fluorescence arises from fluorescent tags, included in the reagent and associated with the polynucleotides upon amplification.
• C. Preferred Positioning Elements[0110]
• Preferred positioning elements are discussed below.[0111]
• 1. Non-Wetting Positioning Elements[0112]
• A[0113]positioning element979 may be formed by a non-wetting material disposed to contact a microfluidic sample. The physio-chemical properties of the non-wetting material are chosen upon considering the type of liquid forming the microfluidic sample. For example, where the microfluidic sample is an aqueous sample, the positioning element preferably comprises a hydrophobic material. An exemplary hydrophobic material includes a non-polar organic compound, such as an aliphatic silane, which can be formed by modifying an internal surface of microfluidic device901. For microfluidic samples formed of organic solvents, the non-wetting material may comprise a hydrophilic material.
• When[0114]microfluidic sample808encounters positioning element979, the liquid of the microfluidic sample experiences an increased surface tension atdownstream interface810, which increased surface tension inhibits continued downstream motion ofmicrofluidic sample808. Increasing the gas pressure difference between upstream and downstream portions of the microfluidic sample overcomes the resistance and moves the microfluidic sample downstream.
• 2. Capillary Assisted Positioning Elements[0115]
• Referring to FIGS. 10[0116]a-10c, another type of positioning element may be formed by modifying the dimensions of the microfluidic channel to form a capillary assisted positioning element (CAFB)700. A CAFB comprises anupstream feed zone702, aloading zone704, and astop zone704. Amicrofluidic sample720 encountering the CAFB moves downstream until adownstream interface710 of the microfluidic sample contactsupstream surfaces714 of theloading zone706. At this point, capillary action causes the microfluidic sample to move downstream until thedownstream sample interface710 encounters theopening712 between theloading zone704 and thestop zone706. Surface tension resists the tendency of the microfluidic sample to continue downstreampast opening714. Thus, themicrofluidic sample720 is positioned at a predetermined location along the channel axis with respect topositioning element700.
• The volume of the microfluidic sample encountering the CAFB preferably has a larger volume than a volume of the[0117]loading zone704 to ensure that the microfluidic sample will advance fully to opening. For fluids that have similar surface tensions and interface properties as water, the depth d₁of theloading zone704 is preferably about 50% or less of the respective depths d₂, d₃of the stop and feed zones.
• The tendency of a microfluidic sample to move in a given direction is governed by the ratio between the mean radius of curvature (MRC) of the front of the microfluidic sample and the MRC of the back of the microfluidic sample. These curvatures depend upon the contact angle of the fluid of the sample and the dimensions of the zone in which the microdroplet is moving. A MRC r[0118]₁of a microdroplet interface in the loading zone is preferably smaller than a MRC r₂of a droplet interface within the feed zone or a MRC r₃of a droplet interface within the stop zone. The MRC r₂is preferably larger than the MRC r₃. Thus, the radius of curvature of the downstream microdroplet interface increases upon encountering the stop zone thereby inhibiting further downstream movement. Preferably, the contact angle of the fluid with the wall is substantially constant throughout the capillary assisted loading zone.
• 3. Vented Positioning Elements[0119]
• Referring to FIGS. 11[0120]a-11c,apositioning element500 operates to position amicrofluidic sample502 by reducing the gas pressure acting upon anupstream portion504 of the microfluidic sample relative to the gas pressure acting upon adownstream portion506 of the microfluidic sample.Positioning element500 includes avent508 disposed in gaseous communication with azone510 along whichmicrofluidic sample502 moves. Vent508 preferably communicates withzone510 via a passage526. The zone may be for example, a channel or conduit.Positioning element500 may also include asecond positioning element516, such as a non-wetting material, to substantially prevent fluid from the microfluidic sample from contacting the vent.
• An open state of a[0121]valve512 allows passage of gas betweenzone510 and vent508. A closed state ofvalve512 prevents such passage of gas.Valve514 is preferably thermally actuated and includes amass514 of TRS.
• An[0122]actuator518 is disposed upstream ofpositioning element500.Actuator518 is preferably a gas actuator and may include aheat source520 to heat a gas associated withactuator518.Actuator518 may include apositioning element522, such as non-wetting material, to substantially prevent fluid from the microfluidic sample from entering therein.
• Positioning[0123]element500 preferably operates as follows. Referring to FIG. 11a,microfluidic sample502 moves downstream in the direction ofarrow524. Microfluidic sample is preferably moved by a gas pressure provided from an upstream actuator, which is not shown in FIGS. 9a-9c. The gas pressure acts uponupstream portion504.
• Referring to FIG. 11[0124]b, whenupstream portion504 passes the opening ofvent508, the upstream gas dissipates throughvent508, thereby reducing the upstream pressure. The pressure reduction, which preferably equalizes the downstream and upstream pressures, reduces or eliminates the motive force tending to urge the microfluidic sample downstream.
• Referring to FIG. 11[0125]c,valve512 is closed to prevent passage of gas betweenzone510 and vent508. Preferably,TRS514 moves into passage526. Upon closingvalve512, the actuation ofactuator518 provides a motive force to movemicrofluidic sample502 downstream in the direction ofarrow528 for further processing.
• 4. Active Fluid Positioning Elements[0126]
• Referring to FIGS. 15[0127]a-15c, amicrodroplet preparation module652 has amicrodroplet preparation zone650, an activefluid positioning element654, anactuator656, and avalve658. Asecond actuator660 is operatively associated with theactive positioning element654 to introduce amicrofluidic sample666 to themicrodroplet preparation zone650.Second actuator660 is preferably located upstream fromvalve658.Microdroplet preparation module652 prepares a microdroplet668, which has a predetermined volume from themicrofluidic sample666 received therein.
• In operation,[0128]microfluidic preparation module652 receives themicrofluidic sample666, which moves downstream because of a motive force provided by thesecond actuator660. The motive force is preferably an upstream gas pressure, which is greater than a downstream gas pressure acting upon themicrofluidic sample666. The microfluidic sample moves downstream until adownstream portion670 thereof encountersactive positioning element654, which preferably comprises asensor672 having electrical leads674. The leads674 are in electrical communication with I/O pins of the microfluidic device to allow signals fromsensor672 to be received by a DAQ.
• [0129]Sensing element672 is preferably a pair of electrical contacts. To sense the presense of the liquid,DAQ126 applies a small voltage across leads674 and measures the resultant current. As the liquid of the microfluidic sample contacts the first and second contacts, the current passing therebetween changes, thereby indicating to DAQ126 that the liquid has arrived atsensor672.
• Upon recognition that the l;iquid has arrived at[0130]sensor672, the DAQ instructssecond actuator660 to decrease a downstream motive force acting upon themicrofluidic sample666. For example, DAQ may reduce a current flowing through aheat source676 associated withsecond actuator660 thereby reducing a temperature of a gas therein. The temperature reduction reduces the gas pressure acting upon aupstream portion678 of microfluidic sample thereby inhibiting the downstream motion of themicrofluidic sample666. The microfluidic sample is positioned such that afirst portion680 is located downstream ofactuator656 and asecond portion682 is located upstream ofactuator656.
• To prepare microdroplet[0131]668,DAQ126 actuates actuator to provide a motive force which prepares the microdroplet668 from thefirst portion680 ofmicrofluidic sample666. Microdroplet668 moves downstream while thesecond portion682 of themicrofluidic sample666 moves upstream fromactuator656. During microdroplet preparation,valve658 may be closed to substantially isolate the actuator656 fromsecond actuator660 and other upstream portions of the microfluidic device.
• The active positioning element preferably operates as a closed loop element that provides feedback from[0132]sensor672 to the DAQ. The feedback is indicated when a microfluidic sample has reached a predetermined position within the microfluidic device. Upon receiving the feedback, the DAQ changes the state of the actuator providing the motive force to move the microdroplet.
• While the above invention has been described with reference to certain preferred embodiments, it should be kept in mind that the scope of the present invention is not limited to these. Thus, one skilled in the art may find variations of these preferred embodiments which, nevertheless, fall within the spirit of the present invention, whose scope is defined by the claims set forth below.[0133]

Claims (28)

What is claimed is:

1. A microfluidic device, comprising:

a first gas actuator to provide a gas pressure sufficient to move first sample material between first and second spaced apart locations of the microfluidic device;

a second gas actuator to provide a gas pressure to move second sample material between third and fourth spaced apart locations of the microfluidic device, the second gas actuator being spaced apart from the first gas actuator.

2. The microfluidic device ofclaim 1, wherein the first location is spaced apart from at least one of the third and fourth locations.

3. The microfluidic device ofclaim 1, wherein the first location is spaced apart from both the third and fourth locations.

4. The microfluidic device ofclaim 1, wherein the second location overlaps the third location and the second sample material comprises at least a portion of the first sample material.

5. The microfluidic device ofclaim 1, wherein the first location comprises a first sample processing zone and the first sample material comprises processed sample material prepared at the first sample processing zone.

6. The microfluidic device ofclaim 5, wherein the first sample processing zone is an enrichment zone and the first processed sample material comprises enriched sample material.

7. The microfluidic device ofclaim 5, wherein the first sample processing zone is a cell lysing zone and the first processed sample material comprises intracellular material.

8. The microfluidic device ofclaim 5, wherein at least one of the second, third, or fourth locations comprises a detection zone configured to obtain data indicative of the presence of a sample material.

9. The microfluidic device ofclaim 1, wherein the first and second gas actuators each comprise a heat source in thermal contact with a volume of gas, whereby actuation of the heat source of a respective gas actuator causes the gas pressure provided by the gas actuator.

10. The microfluidic device ofclaim 1, wherein the device comprises a substrate and the first, second, third, and fourth locations and the first and second gas actuators are integral with the substrate.

11. The microfluidic device ofclaim 1, further comprising a valve disposed to isolate the second gas actuator from the first gas actuator.

12. A microfluidic device for processing a microdroplet of sample, comprising:

a first gas actuator to provide a gas pressure sufficient to move the microdroplet between first and second processing zones of the microfluidic device; and

a second gas actuator to provide a gas pressure to move the microdroplet between the second processing zone and a third processing zone of the microfluidic device.

13. The microfluidic device ofclaim 12, wherein the first gas actuator is spaced apart from the second gas actuator.

14. The microfluidic device ofclaim 13, further comprising a valve to isolate the second gas actuator from the first gas actuator.

15. The microfluidic device ofclaim 12, wherein the first processing zone is an enrichment zone and the microdroplet comprises an enriched amount of cells.

16. The microfluidic device ofclaim 12, wherein the second processing zone is a lysing zone and the microdroplet comprises intracellular material released from cells of the first microdroplet.

17. The microfluidic device ofclaim 12, wherein the third processing zone is a detection zone configured to obtain data indicative of the presence of a sample substance present in the microdroplet.

18. The microfluidic device ofclaim 17, wherein the sample substances comprise polynucleotides.

19. The microfluidic device ofclaim 12, wherein the device comprises a substrate and the first, second, and third locations and the first and second gas actuators are integral with the substrate.

20. A method for moving a microdroplet of sample material within a microfluidic device, comprising:

providing, at a first location of the microfluidic device, a first gas pressure sufficient move the microdroplet between first and second processing zones of the microfluidic device; and

providing, at a second, different location of the microfluidic device, a second gas pressure to move the microdroplet between the second processing zone and a third processing zone of the microfluidic device

21. The method ofclaim 20, wherein the microfluidic device comprises a substrate and the first and second gas pressures are provided by gas actuators that are integral with the substrate.

22. The method ofclaim 20, further comprising actuating a valve to isolate the second processing zone from the first processing zone.

23. A method for moving a microdroplet of sample material within a microfluidic device, comprising:

providing, at a first location of the microfluidic device, a first gas pressure sufficient to move the microdroplet from a first microdroplet position within the microfluidic device to a second microdroplet position within the microfluidic device; and

providing, at a second location of the microfluidic device, a second gas pressure to move the microdroplet from the second microdroplet position to a third microdroplet position within the microfluidic device.

24. The method ofclaim 23, wherein the microfluidic device comprises a substrate and the first and second gas pressures are provided by gas actuators that are integral with the substrate.

25. The method ofclaim 22, further comprising actuating a valve to isolate the second microdroplet position from the first microdroplet position.

26. A microfluidic substrate comprising:

a microfluidic network,

a first gas actuator coupled to said network at a first location, wherein said first gas actuator, when actuated, provides gas pressure to move a microfluidic sample within the network, and

a second gas actuator coupled to said network at a second location, wherein said second gas actuator, when actuated, provides gas pressure to further move at least a portion of said microfluidic sample within said network.

27. The microfluidic substrate ofclaim 26 further comprising a valve coupled to said network at a third location whereby said valve, when closed, substantially isolates the second gas actuator from the first gas actuator.

28. The microfluidic substrate ofclaim 26 further comprising a microfluidic process zone to receive and process the microfluidic sample upon actuation of the first gas actuator.

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